WELLHEADS & COMPONENTS

Wathik M. Alhashimi, P.Eng.

 Wellhead Components and Considerations
Features in common:
• All wells are lined with steel pipe (casing) to allow unobstructed access to the target reservoir.
• Up to four casing strings may be installed and each string is cemented in place to mechanically
support the pipe and hydraulically isolate the target reservoir from groundwater sources and other
formations.
• Most wells also include one or more strings of pipe or tubing to recover or “produce” the reservoir
fluids, to inject fluid into the reservoir or to allow other well operations.
• All wells are capped by an assembly of steel pipe and fittings (wellhead).
• The wellhead’s function is to contain the reservoir or well fluid and to allow safe access to the casing
and tubing for the life of the well.

• The function of the wellhead above the wellbore is fundamentally linked to the function of the various strings
of casing and tubing that run down inside the wellbore.
 Casing
A typical basic well is installed with strings of casing (each cemented into place) plus a short length of conductor pipe .
Conductor pipe is set to prevent sloughing and water influx while drilling through the soft and generally weak material near surface.
It may also capture and enable the recirculation of drilling fluid during subsequent drilling operations.
Conductor pipe is typically set at a depth of less than 30 metres, cut off at ground level, light weight and not used to support any
permanent wellhead equipment and equipped with a mounted diverter system in the early stages of certain drilling operations that
carry a heightened risk of shallow gas kicks.
Surface casing, where required, is installed to isolate the uppermost part of the well and to ensure the integrity of the wellbore while
drilling deeper. Once the surface casing is landed the casing is cemented to the borehole wall. The first wellhead components are then
attached and begin their function as a well control device.
Surface casing is the foundation of the well, providing the platform on which the wellhead is mounted and securing the existing hole for
subsequent drilling, easily recognizable as the first and outermost casing string and more common in deeper or high-pressure wells or
where there is a requirement to isolate shallower fresh water from deeper saltwater sources or hydrocarbons.
Production casing is set across or on top of the target formation and cemented into place. It is always tied back to surface where
wellhead components seal and isolate the annular space between the production casing and the previous casing string. The wellhead
offers outlets to access the inside of the production casing.
Production casing is the string through which larger well servicing operations are conducted and the well completion equipment is set.
In situations where surface casing is not installed, the production casing will be cemented from final total depth (FTD) to the surface.
Production casing may perform as follows:
• Serve as the platform on which the wellhead is mounted when surface casing is not installed. Conduct produced fluid to the
surface in some cases (e.g., commonly used as the production string for gas in sweet, shallow wells where production tubing may
not be used).
• Provide an annulus to vent gases in pumping wells.
• Serve as a conduit for injection purposes in certain cases, most notably steam injections or pressured gas in a gas lift system.
Additional casing strings may be required to isolate intermediate formations (intermediate casing) or to support or provide additional
strength for production operations (production liner). These may be found in deep or complex wells or in shallow horizontal wells where
a liner may serve as the lower portion of the production casing. These additional strings can be sealed to a previously cemented casing
string or cemented and tied back to surface. If tied back to surface, the wellhead is designed to accommodate and support the
additional strings.
House production tubing or other tubulars and lines run down hole from the wellhead at the surface. This creates an accessible annular
space that runs from the wellhead to the target formation.
 Tubing
• In most wells a single tubing string is the main conduit for bringing reservoir fluid to the surface or injecting fluid
from the surface into the target formation. Additional tubing strings may be required if the formation has more
than one interval being accessed and the fluids from the different intervals need to be kept separate from each
other.
• Multiple tubing strings may also be used when a long reservoir section requires access at two or more locations.
• Well monitoring equipment or instrumentation may also require additional tubing strings.
• Each tubing string is supported from the wellhead and may be free hanging, anchored or sealed against the
cemented casing string.
• Multiple tubing strings can be run concentrically (each inside the previous tubing) or be in parallel with each
string suspended separately.
 Instrument and Control Lines
• Wellheads provide safe, sealed access for small diameter tubing or electric lines that may be installed to monitor
well operating conditions, inject chemicals, operate flow control devices or power artificial lift equipment.
• The wellhead serves to suspend, isolate and support these lines.
 Types of Wells
• Individual wellhead designs can vary significantly based on the types of fluid or other materials handled, the flow velocities,
pressures and temperatures encountered.
• Well production and servicing operations over the entire life cycle of the well also impact design.
o Sweet Flowing Wells
o Critical Sour, Sour and Corrosive Wells
o Artificial Lift Wells
o Other Well Types.
 Wellhead

The system of spools, valves and assorted adapters that provide pressure control of a production well.
Diagram of Casing and Tubing
• Subsea wellhead
• A well in which the wellhead, Christmas tree and production-control equipment is located on the seabed.
 Component Requirements Applicable to All Wellheads
American Petroleum Institute (API) provides key manufacturing standards for wellhead components.
• Wellhead components that are certified to API standards carry an API stamp.
• Wellhead equipment that meets API 6A is available in the following standard pressure increments:
o 13.8 MPa
o 20.7 MPa A wellhead component used in flanged wellhead assemblies to
o 34.5 MPa secure the upper end of a casing string. Casing spools or bowls
o 69.0 MPa are available in a wide range of sizes and pressure ratings and are
o 103.5 MPa selected to suit the specific conditions.
o 138.0 MPa
• Standard temperature Appendix B.
Operating ranges
• Conventional operations span -60 to 1210 C (-75 to -1800 F) in 8 ranges (K, L, N, P, S, T, U, V).
• Equipment can have more than one temperature classification meaning the equipment is suitable for use over the entire
range of temperatures covered by these multiple ratings (i.e. a temperature classification of KU means that equipment is
good for use over the entire range of -60 to 121°C).
• Elevated temperature operations span -18 to 3450 C (0 to 6500 F) in 2 ranges (X, Y). Y has the highest temperature rating.
• Note: Elevated temperatures :-Appendix B and API 6A for more information).
• Material Class defines the corrosion resistance required by all components wetted by the retained fluid.
• The seven material classes range from AA (General service: carbon or low alloy steel) to HH (Sour service: corrosion resistant
alloys).
• All sour service materials must conform to NACE MR0175/ISO 15156. (Appendix B for API Material Requirements).
• Product Specification Level (PSL) defines the different levels of technical quality requirements for the wellhead component
(PSL 1 is the baseline. PSL 2, PSL 3, PSL 3G and PSL 4 include additional and ever more stringent requirements to confirm
component suitability for challenging operations (e.g., high pressure, elevated temperature, sour).
 Basic Components of a Wellhead

A wellhead is made up of a series of components that are connected and sealed in various ways.
• Casing Head
• Casing Spool
• Casing Hangers
• Packoff Flange
• Tubing Head
• Lock Down Screws
• Tubing Hanger
• Tubing Head Adaptor
• Christmas Tree
• Gate Valves
• Coiled Tubing Hangers
• Wellhead Feedthroughs
• Surface Casing Vent Assembly
 Pressure Rating Requirements
The pressure rating on all wellhead components must meet or exceed the maximum anticipated service
conditions.
The service conditions of the well may differ over the life of the well.

Full Bore Access Requirements

Wellhead components should allow full bore access to the casing or tubing to which they are connected.
 Casing Head(Bowl)
• The casing head (casing bowl): the lowest part of the wellhead assembly .
• The bottom of the casing head is configured to attach to the casing below (usually the surface casing).
• The upper inside of the casing head provides a bowl in which the next casing string can be set and sealed .
• The top of the casing head then connects to the next wellhead component.
• A casing head may also be supplied with a landing base plate that takes the weight load off the surface casing and spreads it over the
conductor pipe.
• Access to the annulus between the surface casing and the next casing string is available through side outlets.
• The casing head provides the following functionality:
• Isolates the inside of the surface casing from the outside environment.
• Provides a platform for and a means to test the rig BOP stack during drilling
• operations.
• Supports or transfers the weight of drilling and workover equipment during drilling
• and well servicing operations.
• Allows the next casing string (i.e., intermediate or production casing) to be
• suspended or packed off. This is accomplished by setting a casing hanger and seal against the recessed profile machined into the
upper inside surface (bowl). The hanger is often held in place by lock down screws. The seal formed against the casing string is called
the primary seal.
• Provides access to the surface inner casing annulus for monitoring and fluid return.
• Access is available through side outlets drilled through the casing head.
• One of the side outlets may be converted to a surface casing vent after the well is completed.
• This can then be used to monitor any flows or pressure build-up of gas, water or hydrocarbon liquids within the surface casing annulus.
• These flows or pressure build-ups can indicate a failure in the integrity of the inner casing cement, production casing or annular seals that
may present an environmental hazard.
 Casing Spool
• If a well includes one or more intermediate casing strings between the surface and production casing, the next
component after the casing head is the casing spool (.
• The bottom of the casing spool mounts on top of a casing head (or previous spool) and the top connects to the
next spool or tubing head assembly.
• The spool is designed so the bottom bowl or counterbore will allow a secondary seal to be set on the previous
casing string while the top bowl will hold a casing hanger to suspend and allow a primary seal around the next
string of casing.
• Multiple casing spools may be used, one on top of the other, to hang intermediate casing strings and the final
production casing string.
Functionality
• Allows for a secondary seal on the previous casing string in the counterbore. With a secondary seal in place,
flange or hub seals and casing hanger seals are isolated from internal casing pressure.
• Provides a port for pressure testing primary and secondary casing seals and flange connections.
• Provides a platform to support, seal and pressure test the BOP during drilling and well servicing operations.
• Provides a load shoulder and controlled bore in the top bowl to support the next casing hanger and enable a
primary seal for the next intermediate or production casing.
• Provides annular access for fluid returns or fluid injections and pressure monitoring. Access is available
through side outlets drilled in the spool assembly.
functionality
• Allows for a secondary seal on the previous casing string in the counterbore. With a
secondary seal in place, flange or hub seals and casing hanger seals are isolated from
internal casing pressure.
• Provides a port for pressure testing primary and secondary casing seals and flange
connections.
• Provides a platform to support, seal and pressure test the BOP during drilling and well
servicing operations.
• Provides a load shoulder and controlled bore in the top bowl to support the next
casing hanger and enable a primary seal for the next intermediate or production
casing.
• Provides annular access for fluid returns or fluid injections and pressure monitoring.
Access is available through side outlets drilled in the spool assembly.
Wellhead Spool Types
 Casing Heads
• The casing head (casing bowl): the lowest part of the wellhead assembly .
• The bottom of the casing head is configured to attach to the casing below (usually the
surface casing).
• The upper inside of the casing head provides a bowl in which the next casing string can be
set and sealed .
• The top of the casing head then connects to the next wellhead component.
• A casing head may also be supplied with a landing base plate that takes the weight load off
the surface casing and spreads it over the conductor pipe.
• Access to the annulus between the surface casing and the next casing string is
available through side outlets.
• The casing head provides the following functionality:
• Isolates the inside of the surface casing from the outside environment.
• Provides a platform for and a means to test the rig BOP stack during drilling
• operations.
• Supports or transfers the weight of drilling and workover equipment during drilling
• and well servicing operations.
• Allows the next casing string (i.e., intermediate or production casing) to be
• suspended or packed off. This is accomplished by setting a casing hanger and seal
against the recessed profile machined into the upper inside surface (bowl). The
hanger is often held in place by lock down screws. The seal formed against the casing
string is called the primary seal.
• Provides access to the surface inner casing annulus for monitoring and fluid return.
• Access is available through side outlets drilled through the casing head.
• One of the side outlets may be converted to a surface casing vent after the well is
completed.
• This can then be used to monitor any flows or pressure build-up of gas, water or
hydrocarbon liquids within the surface casing annulus.
• These flows or pressure build-ups can indicate a failure in the integrity of the inner casing
cement, production casing or annular seals that may present an environmental hazard.
 Casing head with base plate

The adapter between the first casing string and

either the BOP stack (during drilling) or
the wellhead (after completion).
This adapter may be threaded or welded onto the
casing, and may have a flanged or
clamped connection to match the BOP stack or
wellhead.
 Casing Spool
A wellhead component used in flanged wellhead assemblies to secure the upper end of a casing string. Casing
spools or bowls are available in a wide range of sizes and pressure ratings and are selected to suit the specific
conditions.
• A Spacer Spool is a pressure containing piece of equipment that can be used beneath or in the middle of drill
through equipment.
• Spacer Spools are used in the Oil Drilling Industry often for wellhead extension, and Blowout Preventer spacing.
• Adapter spools may be single piece forged or welded construction.
• Adapter spool have end connections of different sizes, pressure ratings and/or designs. Adapter spool is
designed to avoid the bolt fit up fouling and to allow connection of different drilling equipment.
• An extension added to a short face-to-face valve to conform to standard API 6D (or ISO 14313: 1999) face-to-face
dimensions.
• API 6D specifies requirements and gives recommendations for the design, manufacturing, testing and documentation
of ball, check, gate and plug valves for application in pipeline systems.
A Double Studded Adapter (DSA) is commonly used to connect flanges with different nominal sizes, pressure ratings, and
configurations.
Tubing Head Threaded by Threaded or Welded
 Tubing Head
• The tubing head assembly provides a means to suspend and seal the production tubing in the wellhead .
• The tubing head is the top spool in the wellhead assembly and is installed after the last casing string is set.
• The bottom of the tubing spool includes a counterbore that can be used to set a seal against the production
casing or casing hanger.
• The top of the tubing head provides a landing shoulder and a seal bore for landing and enabling a seal to the
tubing hanger.
• Above the tubing head is the tubing head adaptor which provides a transition to the Christmas tree (also
sometimes referred to as the wellhead top section).
A tubing head is a wellhead component consisting of a body with two flanges, supports the tubing hanger and
provides a means of attaching the Christmas tree to the wellhead.
It seals off the pressure between the casing and tubing annulus and connects with the tubing adapter on the top.
 A tubing head is a mechanical fitting used on the wellhead structures of crude oil wells.
It is generally located in the lower section of the wellhead above the casing hanger and
Tubing Head casing spool. The head features a profiled inner surface designed to accept the tubing
hanger which supports and seals the tubing conduit

1.Tubing head structure

Tubing head is usually a spool with both flanged ends which is set on the top
flange of casing head to hang tubing hanger and seal the annular space between the tubing string and oil-layer casing and which consists of
tubing head spool and tubing hanger.
2.Functions
1) hang the tubing string inside well;
2)seal the annular space between tubing and casing;
3)give a crossover to connect casing head downwards and to connect x' mass tree upwards;
4)provide both side outlets in tubing head spool body through which to execute injection and well-wash operation.
Tubing hanger is an assembly to support tubing string and seal the annular space between tubing and casing which is connected with tubing
and seated into tubing hanger spool by tubing gravity.
It is convenient to operate and replace wellhead so that it is widely used for intermediate depth well and common well.
 Tubing Head Flanged by Threaded or Welded
• The Tubing Head is the uppermost spool in a wellhead assembly.
• It provides a means to support and seal a tubing string.
• The upper section has a straight type bowl and a 45 degree load shoulder to support and seal the tubing string
by means of a tubing hanger.
 Top and Bottom Connection Flanged or Clamp Hub
• Tubing heads with flanged or clamp hub connections top and bottom may be used in any operation.
• Tubing heads with flanged or clamp hub connections top and bottom should be used for operations where
pressures are expected to exceed 20.7 MPa or for lower pressures in critical sour applications.
• Tubing heads with flanged or clamp hub connections top and bottom should be used for operations where the
following conditions exist:
o There is a need to pressure test the annulus between production casing and the previous casing string.
o There is a need to isolate the production casing from any structural loads.
o Replacement of tubing head may be required.
o Multiple casing strings exist.
 Flanged by Threaded or Welded
• Flanged top by thread on or weld on tubing heads may be used in specific low-risk operations.
• Flanged top by welded should be used in thermal operations such as cyclic steam injection (CSS) and
steam assisted gravity drainage (SAGD).
• The flanged top configuration has advantages over threaded configurations that allow tubing to be run
under pressure (e.g., locking screws for tubing hanger retention).
• Its limitation is that it does not provide a secondary seal on the production casing and therefore no
ability to pressure test between the production casing and the previous casing string (usually the surface
casing).
 Threaded by Threaded or Welded
• The use of a tubing head with a threaded hammer cap top shall be limited to low pressure wells not requiring sour
service (as per NACE MR0175/ISO 15156).
• With this configuration, the threaded hammer cap locks down the tubing hanger and may energize seals.
• The hanger will not provide well control without the cap.
• An adapter will be required to install a BOP.
• The adapter may be proprietary and not interchangeable with other manufacturers.
• These designs have historically been rated at working pressures of 10.3 MPa to 20.7 MPa.
• Risks, including tool availability, throughout the life cycle of the well which should be considered.
• Threaded by threaded tubing heads can be designed which do not rely on a cap for hanger and seal retention or are
intended for specific applications like coiled tubing suspension.
 Casing Hangers
• Both casing head and casing spool assemblies may require the use of casing hangers .
• Casing hangers attach to the end of a given casing string and suspend and seal the casing string in the top bowl of a casing
head or spool. Casing hangers come in two main varieties: slip type and mandrel.
• Slip type hangers are installed around the casing after it is run, either before or after the casing is cemented into place.
• They are also used as a contingency when casing is stuck as they allow the casing to be cut off and set where it sits.
• Mandrel type hangers are threaded onto the casing.
• They provide superior well control when landing the hanger and improve the annular seal.
• Often mandrel type hangers may be equipped with flutes for fluid bypass. These flutes allow for cement returns to bypass
the hanger and return to surface.
• If this is the case, a separate primary seal is run after cementing.
• When a casing hanger is used, shallow intermediate strings are usually suspended from the hanger and then cemented to
surface.
• Longer intermediate and production strings that are not cemented to surface are usually cemented while the casing is
suspended in tension from the rig traveling block.
• After the cement has set for a few hours the traveling block pulls a calculated tension on the casing above the cement and
it is at this point the hanger is set in the bowl.
• Casing hangers are often called slip and seal hangers (also known as automatic casing hangers) as they are designed with
built-in seals.
• Automatic casing hangers typically require a minimum weight to energize their seal.
• Manual casing hangers (manual slips) may occasionally be run without seals in shallow wells where a primary seal is then
installed whenever the BOP is removed.
• A hanger may also be held in-place in the upper bowl of a casing head or spool assembly using lock down screws (also
called hold-down screws).
• The casing hanger provides the following functionality:
• Suspends the load of the casing string from the casing head or spool.
• Centers the casing in the head.
• Provides a primary seal against the inside of the casing head and isolates the
• casing annulus pressure from upper wellhead components.
• In the event of a stuck casing, a slip type casing hanger may be required to land the stuck casing.
 Casing Hangers
The subassembly of a wellhead that supports the casing string when it is run into the wellbore. The casing hanger provides a means of ensuring
that the string is correctly located and generally incorporates a sealing device or system to isolate the casing annulus from upper wellhead
components.
Functionality
• Enables the suspension of the tubing.
• Allows for sealing of the annulus between the tubing and the production casing.
• Allows access to the annulus between the tubing and production casing (through
• side outlets).
• Provides the makeup flange for the service rig BOPs during well completions and
• interventions.
• Provides a bit guide for running the tubing. Some varieties of tubing heads also provide the following functionality:
• Provides mechanism for locking tubing hanger in place.
• Allows a secondary annulus seal to be set around the top of the production casing
• or casing hanger.
• Provides access for a test port to test primary and secondary seals.
• Allows for correct orientation of equipment to enable running multiple parallel
• tubing strings.
• Tubing Heads may have an increased pressure rating between the top connection and the bottom connection.
• API 6A standards allows for an increase in pressure increments.
• So technically, for example, given proper isolation bolting strength, a 20.7 MPa tubing head assembly could be mounted on a
13.8 MPa casing head or casing spool.
• This is accomplished by isolating the lower pressure connection by the use of a restricted area packoff.
• Lock down screws can be used to support tubing hangers in smaller bores where load shoulder does not exist.
• For 130 or 103 mm (5-1/8” or 4-1/16”) bores, two banks of lock down screws can be used.
• The lower bank is to support and/or position the hanger and upper bank to retain, support and/or energize the seal.
• The risk for lock down screw failure increases dramatically in snubbing operations in a tubing head with dual bank lock down
screws.
• The purpose of lock down screws in tubing heads is dependent on design and usage is not universal; however, they are often
critical to the load bearing capacity of the head as well as for locating the hanger correctly.
 Lock Down Screws
• Lock down screws are designed to hold down or energize seals on a casing or tubing hanger, packoff and bore protector (or wear
bushing) or BOP test plug in the top wellhead bowl.
• There are many variations in designs and purpose.
• There are two common types of lock down screws:
• Internally Threaded Gland Nut
• Threaded Nose Lock Screw
 Internally Threaded Gland Nut
The screw is threaded in the gland nut.
The screw thread is located between the packing and the flange outside diameter.
The screw thread is not exposed to wellbore fluids
• The screw is threaded into the tubing/casing head and the thread is located between the wellbore and the
packing.
• The gland nut is used to energize the packing.
• The screw thread is exposed to wellbore fluids which can impede the function of the lock down screw.
• The following outlines some general procedures for lock down screws:
• Prior to working on or moving lock down screws, pressure should be isolated and bled off from the hanger cavity
using a bleeder tool or alternate method.
• The gland nut should not be backed off to operate the lock down screws.
• All screws should be engaged or backed out equal distances to ensure uniform engagement or opening through
the spool.
• Refer to wellhead vendor for proper engagement measurement and torque to apply.
• Engaging or opening sequences should be performed in a cross pattern similar to flange tightening.
• Operational steps for removing or landing a hanger while snubbing can be found in IRP 15 Snubbing Operations.
• The lock down screw can be ejected from the wellhead if the gland nut is backed out too far while pressure exists.
• Lock down screws should be able to withstand the dynamic loads from the reciprocating motion of a rod string in
artificial lift wells and the torque during the start- up and shut-down of Electric Submersible Pump (ESPs) and
Progressing Cavity Pumps (PCPs).
Threaded Nose Lock Screw
 Packoff Flange
• Packoff flanges are set above a casing head or spool assembly and sealed against the intermediate or
production casing to enable a safe increase in pressure rating between the casing head or spool and
any wellhead equipment above the flange (e.g., a tubing head).
• It is also known as a restricted packoff flange or crossover flange.
• API 6A allows for an increase in pressure increments between components.
• One method to manage increased pressures is to use a packoff flange between wellhead
components.
• A packoff flange may also be used in temporary operations (e.g., pressure testing primary seals) or as
a safety device when drilling out the cement that remains in the shoe joint (or float collar).
 Packoff Flanges
Pack-off flanges are usually used as a cross-over connection to adapt flanges of different pressure ratings or sizes
and provide an extra safety seal of the casing.
 Tubing Hanger

A tubing hanger is a component used in the completion of oil and gas

production wells.
It is attached to the topmost tubing joint in the wellhead to support the tubing
string.

• A tubing hanger (commonly known as a dog nut) is threaded onto the top of a
tubing string and is designed to sit and seal in the tubing head .
• Usually the tubing hanger is run through the BOP and landed in the top bowl of
the tubing head.
• The top of the tubing hanger provides a profile necessary for the lock screws that
secure the hanger in the tubing head.
• The bottom of the tubing hanger provides a taper that sits on the landing
shoulder in the tubing head.
• In a simple, single string completion the hanger carries the weight of the tubing and the tubing is “hung in
neutral”.
• The design of the completion equipment may have an impact on hanger design.
• Consider that a downhole packer allows the tubing to be set in compression, tension or neutral.
• Upward (compression) forces may need to be placed on the tubing string during production or injection
operations.
• The following are situations where this might be considered:
• When the tubing/casing annulus has to be isolated from the fluid handled (e.g., produced water injection or
disposal wells)
• When different intervals need to be isolated from each other.
• When gas will be injected to enhance fluid production (i.e., in a gas lift well).
• Tubing material grade should be consistent with the production/fracture string material.
• Tubing hangers with seal rings or elastomers provide a seal between the tubing hanger and tubing head below
the lock down screws.
• Extended neck tubing hangers (allow for a primary and secondary seal on the tubing hanger.
• In this configuration, a secondary seal packs off inside the tubing head adaptor.
• As a result, the lock down screws are isolated from the wellbore fluids and the primary and secondary seals can
be pressure tested.
• Extended neck tubing hangers are required for sour wells and corrosive wells.
• Because tubing head components and seals are uniquely exposed to production and injection fluids, special
consideration needs to be given to the metallurgy and elastomer seal selection .
• Tubing hangers should come equipped with a profile that enables operator to install a back pressure valve or
isolation plug.
• Risk analysis should be completed if the back pressure valve profile is to be excluded.
• Slip type tubing hangers still exist in the field but they may not provide a seal around tubing for adequate well
control.
• The extended neck with a sealed tubing hanger isolates the produced sour fluids from the top
bowl's lock down screw assemblies and ring gasket of the tubing head.
• Other styles of tubing suspension systems which give the operator the BPV preparation and provide
similar protection to the lock down screw assemblies and ring gasket are acceptable.
• All valves on wellheads on sour wells should be rated for sour service and fit for purpose.
Neck Tubing Hanger
 Wellhead isolation plugs
• Wellhead isolation plugs are designed to engage into a profile and provide a seal in a tubing or casing hanger.
• Back pressure valves (BPV) have a check valve that seals pressure from below and allows fluids to be pumped from above.
• They are used as a barrier to remove, install or maintain equipment above the hanger.
• A two-way check valve has a valve that will seal from either direction. It is used to test equipment above the hanger.
• Tools used to install and retrieve both the BPV and the two-way check valve will unseat the check valve allowing pressure to
equalize during installation and removal.
Isolation Plugs
 Tubing Head Adaptor
The tubing head adaptor provides a transition from the tubing head to the Christmas tree.
• With a tubing hanger that does not have an extended neck interfacing with the tubing head adapter,
the bottom of the tubing head adapter, top of the tubing hanger, seal between head and adapter and
possibly the lock down screws will be exposed to well fluids.
• With an extended neck tubing hanger, the adaptor will provide a secondary seal against the hanger
neck.
• Isolation of seal between the tubing head and adapter and lock down screws from well fluids is
provided.
• The seals also provide means to test the primary and secondary seals on the tubing hanger.
 Tubing Head Adaptors

Tubing head adapter is often used on the top of the tubing head, it
can provide a connection between tubing head and Christmas
tree.
The bottom flange of the adapter matches the tubing head, and
the top flange of the adapter matches the X-MAS tree.
 Flanged Coiled Tubing Hanger and Head
The Flanged Coiled Tubing Hanger uses the quad BOP of the coiled tubing service
unit to seal well pressure and support the string weight, while the Split Slip and Seal
assembly is being installed on the tubing string.
A pressure window is installed above the quad BOP.
The slip rams of the quad BOP hold the string weight, while the pipe rams contain
well pressure. With the anchor bolt lock-down system, positive sealing is assured
regardless of string weight.
After the slip and seal set is installed in the hanger body, push force from the
injector is applied to the string.
The combined compression force and string weight is then locked in using the
anchor bolts.
The flanged hanger is used when higher surface pressure, H2S, and flanged
wellhead components are present.

The entire assembly is sometimes referred to as

a coiled tubing hanger.
Coiled Tubing Feedthrough
 CHRISTMAS TREE

• A Christmas tree is an assembly of gate valves, chokes and fittings included with the wellhead during well completion
(see Figures 16, 17 and 18).
• The Christmas tree provides a means to control the flow of fluids produced from or fluids injected into the well at
surface.
• While Christmas trees come in a variety of configurations based on a number of well design and operating
considerations, typically the bottom connection of the tree matches the top connection of the tubing head and is
generally installed as a unit after production tubing is installed.
• Typical Christmas tree components on a flowing, gas lift or injector well are shown in Figure 16. These components include the following:
• • A minimum of one master valve that will control flows through each tubing string.
• An additional master valve may be required under certain service conditions and well pressures.
• In this case the upper valve would typically be used for routine operations while the lower valve provides a barrier in case the upper valve fails
or needs to be serviced.
• A tee or cross leading to control valves such as production gate valves, surface safety valves, flow control valves or chokes
• Optionally, a swab valve above the tee that permits vertical access to the tubing.
• A tree cap that might be fitted with a pressure gauge.
• The tree cap provides quick access to the tubing bore for bottomhole pressure testing, running down hole equipment, swabbing, paraffin
scraping and other through-tubing well work.
• A tree cap may consist of a bottom hole test adapter which is a tree cap with a top connection providing quick access to the tubing bore and a
flange or clamp bottom connection.
• This type of tree cap must be used in combination with a separate block cross or tee which provides the connection for the flowline.
• The tree cap may also consist of a flow tee, which combines the tree cap with the tee connection for the flowline into a single piece of
equipment.
• As flow tees are commonly used in lower pressure service, they often have threaded bottom and flowline connections.
• The wellhead shall have a means to relieve pressure underneath the tree cap.
• The pressure rating of the Christmas tree shall meet or exceed the maximum anticipated wellhead shut-in pressure or reservoir pressure,
whichever is higher.
• A Christmas tree may be modified based on well operating conditions, fluids produced and recovery methods. In the case of an artificial lift
well that requires a rod string to run through the Christmas tree (e.g., reciprocating rod pumping (RRP) or PCP, see Figure 17), the
configuration is adjusted as follows:
• The master valve is either removed or incapacitated to prevent accidental closure.
• A polished rod BOP is added that can seal around the polished rod if required.
• The polished rod BOP seal ram may be activated either manually or hydraulically.
• A stuffing box is added that provides a seal around the moving polished rod.
• An environmental stuffing box may be included that seals across the tubing bore in the event a polished rod breaks and is pulled or ejected
out of the stuffing box. It may be integrated into the stuffing box itself or be installed as a separate component above or below the stuffing
box.
• Under more demanding operating conditions (e.g., high pressures or corrosive or erosive fluids) a block cross or tee, in conjunction with a
bottom hole test adaptor, should be used rather than a combination of flow tee and test adapter for the top fitting on the wellhead.
X-Mas MASTER Valve
Tree Cap
Generally, the wellhead consists of three components:
(1) the casing head,
(2) (the tubing head, and
(3) (the Christmas tree.
The casing head consists of heavy fittings that provide a seal between the casing and the surface.

• Two types of wellhead chokes are used.

• (1) positive (fixed) chokes and
• (2) adjustable chokes.
• Placing a choke at the wellhead means fixing the wellhead
pressure and, thus, the flowing bottom-hole pressure and
production rate.
 Christmas Tree for Flowing Well

In petroleum and natural gas extraction, a Christmas tree, or

"tree", is an assembly of valves, casing spools, and fittings
used to regulate the flow of pipes in an oil well, gas well,
water injection well, water disposal well, gas injection well,
condensate well, and other types of well.
Christmas Tree on Rod Pumping Well
 Christmas Tree on Dual Completion Well
Dual Completion - Dual Tubing Wellhead & Christmas Tree is used for
extracting two oil reservoir at the same time and also independently.
It allow put down two tubings into the same casing.
Can seal the different two oil reservoir with dual packer and single
packer.
 Gate Valves
• Gate valves are on/off pressure control devices designed to be operated in either the fully open or fully closed position.
• API 6A defines a gate valve as a valve assembly with a gate operating within the body, 90° to the conduit, to effect closure.
API 6A gate valves are thru conduit (pass tools), maintain fixed bores and have fixed end to end dimensions for flanged
valves. API 6A gate valves can have flanged, threaded or proprietary end connections.
• There are two main types of gate valves:
o Expanding Gate Valve
o Slab Gate Valve
• The expanding gate valve is also known as the parallel expanding gate valve.
• The gate assembly is split into two segments (gate and segment), with the stem attached to the gate.
• As the gate travels from opened to closed, a set of gate springs collapse the gate assembly with slight clearance between
the gate and seats.
• The segment engages a stop at closed or opened position.
• The gate stop is in the valve bonnet for opened position and at valve body bottom for closed position.
• The segments with the stem attached continues to travel, sliding on the tapered surface, spreading the gate and segment
apart.
• Tightening the handwheel energizes the seal that is provided between the gate/segment, seats and seat pockets in the
body.
• In this type of valve, the gate must always be wedged at opened or closed.
• The stem will always be in tension or compression.
• This valve has a stem injection fitting on the bonnet neck used to mitigate minor stem packing leaks using injectable plastic.
 Slab Gate Valve
Slab gate valves are comprised of a single gate unit which raises and lowers between two seat rings.
Due to the fact that the gate slides between the seats, slab gate valves are suitable for the medium with suspended
particles.
 Expanding Gate Valve
Provides a superior bi-directional mechanical seal because the two-
piece gate assembly expands against the seating areas in the open or
closed position.
The greater the torque, the tighter the seal.
 Valve
Positions
• The slab gate valve uses a single unit gate, attached to the stem and travels from closed to opened position.
• Line pressure is used to affect a seal. At either opened or closed position, the gate must be allowed to float freely. Hence the
handwheel must be backed off 1⁄4 to 1⁄2 turn.
• The stem will not be stressed except during travel. The seal between gate and seat is provided with pressure from the
upstream side, pushing the seat and gate to the downstream seat.
• There are variations to the slab gate available (e.g., a split gate design where the gate is split into two halves and kept apart by
helical springs).
• The gate/seat seal still follows the slab gate design and handwheel must be backed off.
• It is important to distinguish between expanding or slab gate valves.
• Slab gate and split slab gate valves typically back seat on the stem rather than providing an injection fitting.
• Backseating allows for field replacement of stem packing and stem bearings and shear pin.
• Expanding gate valves do not have back seat capability.
• Valves with two stems are known as balanced stem valves, where pressure across the stem is balanced thereby reducing
operating torque.
• The following are methods of moving the gate:
• Direct connection to the valve stem with a hand wheel.
• Hand wheel diameter is usually less than or equal to the end-to-end dimension to avoid interference.
• Hand wheel on gear operator.
• This method increases the number of turns and reduce operating torque
Ball screw.
• Using ball bearings on a screw tack to reduce friction. Primarily used for large bore fracturing valves and high-pressure gate
valves.
• Hydraulic/pneumatic actuators. Using hydraulic or compressed air to move the stem.
• Electric motorized actuators connected to the stem directly and rotate it using an electric motor.
• Seat injection fittings can be found in some split gate valves and high-pressure expanding gate valves for gate sealant injection
to seal between the gate and seat.
• These fittings are installed along the conduit centerline straddling the stem centerline.
• Flow control valves or chokes can be used to regulate the flow of liquids and gas into or out of a well.
• While technically these components lie outside the scope of IRP 5, when used correctly, they can optimize recovery and
minimize tree and flowline damage caused by erosion and cavitation.
• Good operating and monitoring procedures are essential.
• If a choke washes out the wellhead or flowline can erode quickly to the point of failure.
 Coiled Tubing Hangers
• For wells completed using coiled tubing the coiled tubing hanger and head (Figure 21) may be placed above
the tubing head (e.g., coiled tubing functioning as a velocity string, instrumentation string or running of small
diameter logging tools to evaluate well conditions).
• Or, depending on its function, it may be hung alongside a tubing string.
• In some cases the coiled tubing may be hung above the master valve of the Christmas tree.
• Thermal Operations for a thermal wellhead example that includes a coiled tubing configuration.
• IRP If coiled tubing runs through a master valve on a Christmas tree the master valve handle should be either
removed or chained and locked during normal production operations to prevent accidental closure.
• If coiled tubing runs through a master valve on a Christmas tree an additional means of well control shall be in
place (e.g., a second master valve run above the coiled tubing hanger).
 Wellhead Feedthroughs
Wellheads can be designed to accommodate a variety of small diameter strings and lines that are used for a
number of purposes.
For example, small diameter chemical injection strings are used for corrosion control, de-waxing, scale inhibition,
emulsion breaking or viscosity reduction. Subsurface safety control valves (tubing and annular) require lines
running through the wellhead.
Instrumentation used to monitor downhole pressures and temperatures is also common in some applications.
• Feedthroughs present an extra risk in wellhead design as they provide a potential leak path through the
wellhead.
• Feedthroughs need to be carefully considered and alternatives implemented where possible to lower the
possibility of leaks.
• Feedthroughs that run through and exit via wellhead equipment shall be sealed and packed off at surface and
rated to the working pressure of the wellhead.
• Feedthroughs that run through and exit via wellhead equipment should be pressure tested to a value
determined by operator’s risk assessment.
• The electric feedthrough connector for an ESP shall provide an electrically grounded, gas-tight seal that is fit
for the well’s operating conditions and the surface environment.
• Tubing based feedthroughs present a unique risk to well control.
• Considered in the design of coiled tubing and capillary tube feedthroughs:
o The packoff and seals between the tube and the wellhead.
o The surface termination of the tube.
o The material characteristics of the tube exposed to the environment.
o Bottomhole pressures (i.e., coiled tubing provides a conduit for bottomhole pressures to come to surface
if the coiled tubing fails).
o Corrosion of tubing based feedthroughs above the wellhead has been experienced by some operators.
o The temperatures seen in thermal wells can increase localized corrosion due to condensation above the
wellhead.
 Connections
Connections provide a secure, leak free joint between wellhead components.
The five basic connection types commonly used in wellhead design are discussed in the following sections:
o Threaded
o Welded
o Flanged
o Clamp
o Hub
• Less common, such as sliplock connections (see Sliplock) and connections unique to coiled tubing.
Threaded :With a threaded connection, components are directly threaded onto the previous component.

o Casing head to surface casing connections o Bull plugs

o Casing head to upper wellhead components o Pressure and temperature gauges
o Side outlets o Needle valves
o Tubing hangers o Bottom hole test adapter or fluid sampling port
o Tubing heads o Polished Rod BOPs
o Adaptors o Polished Rod Stuffing boxes
o Valves o Plunger lift lubricator
o Flow tees o Back pressure valve
o Pipe nipples o Valve Removal (VR) Plugs
o Erosion (e.g. sand) or corrosion monitoring
probes
 Welded
• Wellhead equipment can be manufactured using welding.
• Examples are flanged outlets, spools, tees and crosses.
• These welds are part of the manufacturing process and governed by API 6A, ASME Section IX and
manufacturer’s procedures.
• It is difficult to control weld variables in a field environment.
• This can affect the quality of the weld.
• Field welding of wellhead equipment should only be performed for attachments to pipe or casing.
• Connections to pipe (typically, but not limited to, well casing) are typically performed using one of three
methods: Socket Weld, Slip-on Weld or Butt Weld.
• A socket weld involves insertion of pipe into a recessed area of a fitting or flange and fillet welding the exterior
surface. Socket welds are typically used for smaller diameter pipe and fittings.
• A slip-on weld is similar to a socket weld with the addition of a fillet weld on the inside of the connection.
• Slip-on weld connection is the most common means of attaching a casing or tubing head to casing.
• In this application, a fillet weld is applied to the lower, outside connection where the casing head slips over the
casing and to the upper, inside connection where the casing terminates in the casing head.
• This allows for a test port between the welds to pressure test the sealing integrity of the welds.
• Designs using an O-ring in place of the upper weld should not be used.
• The heat input necessary to accomplish a sound weld is likely to compromise the integrity of the O-ring.
 Flanged
• Flanged connections involve two flanges bolted together on the exterior of the component housing.
• Each flange has a ring groove and the connection is made up with a ring gasket to enable a seal between the
flanges.
• Flanged connections can be used in any application.
• They may be used with the following:
o Casing head to casing spool or BOP stack connections
o Side outlets
o Casing spools
o Spacer spools
o Tubing heads
o Adaptors
o Valves
o Flow tees or crosses
o Bottom hole test adaptors
o BOPs
o Polished rod stuffing boxes
o Plunger lift lubricators
 Studded
• Studded connections involve one component that has studs threaded into its housing and a second
component with a flange bolted to the studs.
• Like flanged connections, studded connections include a ring groove and are made up with a ring gasket to
create a seal between the components.
• Casing head to casing spool or BOP stack connections
• Side outlets
• Casing spools
• Spacer spools
• Tubing heads
• Adaptors
• Valves
• Flow tees or crosses
• BOPs
• Stuffing boxes
Studded connections are typically used in the following operations:
• For pressure ratings at or above 20.7 MPa or higher risk operations.
• In any operations where there are requirements to shorten the height or length of the wellhead components.
• In any operations where there is a need to reduce the bending moment on
• equipment.
• Studded connections allow for the installation of a test port to meet requirements of pressure testing between
primary and secondary seals.
 Clamp Hub
• A hub is the enlarged end of a wellhead component that will be used to make a connection.
• With a clamp hub connection, the hubs of the two components being joined are squeezed together over a seal
ring or ring gasket and held in-place by a clamp.
• The two clamp halves wrap around the hub and are bolted to each other to a specified torque to provide the
required connection strength and seal rating.
• Clamp hub connections may be used with most wellhead components such as the following:
o Casing heads
o BOP stacks
o Casing spools
o Tubing heads
o Adaptors
o Valves
o Chokes
o Flow tees or crosses
o Swivel joints
• Clamp hubs are typically used for pressures 13.8 MPa to 138.0 MPa or higher risk operations.
• Clamp hubs have the following characteristics:
• Superior ability to align and seal wellhead components and piping modules (compared to flanged or studded
connections) as small differences in alignment are more easily absorbed by this type of connection.
• Higher fatigue resistance than flanged or studded connections.
• Faster make up time than flanged or studded connections.
• Any damage to the face of the hub may compromise the metal to metal seal.
Clamp Hub
 Sliplock
• Sliplock connections may be used with casing head to casing connections.
• With a sliplock connection the components are attached by sliding one over the other and engaging slips and
seals.
• Slip segments on the inner diameter of the sliplock hold the casing tight.
• Seals provide isolation.
• Both slips and typically seals are energized by studs which are torqued to a prescribed setting provided by the
OEM.
• Sliplock connections are typically used in drilling for surface casing or other temporary operations in place of
welded or threaded connections as the sliplock provides a faster connection time than either of these other
methods.
• They may be used in observation style wells where the wellbore is not exposed to formation conditions.
• One of the key concerns to be address is the resiliency of the sliplock seals to all conditions that might be
encountered such as formation and drilling pressures, temperatures and fluids, cyclic loading or fatigue and/or
adverse conditions such as fire and extreme climates (i.e., very hot or cold).
 Sliplock Casing Head
The casing head with a slip-lock quick connector may replace the traditional threaded or welded connections. The slip-lock
eliminates the loss of time produced when the casing or the head thread is damaged, which may occur when the connection has
a large diameter.
Valve Removal Threading on Side Outlet and Tools
 Valve Removal Threading

VR thread and plug standards were first introduced into API 6A in the 19th edition 2004.
Prior to that, threads were provided according to manufacturer’s standards.
IRP Threads should be verified to make sure plug and outlet are compatible prior to installation.
Threads, if present, will be identified beside the outlet with permanent marking.
 Coiled Tubing Connection Types
• Roll-on connectors (may be found in wellheads completed with coiled tubing.
• The end of the coiled tubing and inner diameter are prepared to ensure a good fit and O-rings might be
included to help provide a tight seal.
• The connector body, with its outer diameter grooves and O-rings, is inserted into the coiled tubing. An
installation tool is then applied to crimp the coiled tubing into the connector body grooves.
• A sleeve may then be slipped over the coiled tubing and threaded onto the connector body.
• The threaded connector is then attached to the tubing hanger which suspends the coiled tubing in the
wellbore.
• Roll-on connectors are preferred in shallow gas operations.
• In conventional and in situ heavy oil operations, the most common means of landing coiled tubing strings in a
wellhead involves slips and seals.
• If the coil is exposed to the atmosphere there is a risk of corrosion due to condensation.
• Coiled tubing may also be attached to a connector body with a welded connection.
• Other means of attaching coiled tubing include dimple and grapple connections.
• Dimple connector uses set screws and grapple connector uses slips to mechanically attach to coiled tubing.
Roll-On Connector Dimple Connector Grapple Connector
 Seals
• Seals are used to hydraulically isolate various tubulars and annuli from one another and to provide well control
(i.e., prevent leaking to the environment).
• Seals also provide isolation between the wellhead and any feedthroughs, including but not limited to:
o instrumentation,
o electrical feedthrough equipment
o some coiled tubing applications.
 Seal Composition Elastomer and Graphite/Carbon Seals
• Sealing components in conventional wells and some thermal wells are typically made from elastomers.
• Elastomers are designed to operate within a specified temperature range and offer resistance to a specific set of
chemical conditions including sour corrosive environments.
• Graphite or carbon fibre seals may be used when operating temperatures exceed the service limits of
elastomers.
• The seal elements (rings) are often installed into recesses or grooves machined into the outer surface of the
component or a bushing that seats into the housing (e.g., for secondary seals, tubing or casing hangers or
adaptors). Pressure is then applied to energize the seals by setting weight on the seal, mechanically applying
pressure or utilizing wellbore pressure.
Metal Seals
• Sealing elements (rings) may also be made from metals.
• Good design and installation practices are essential because it can be difficult to achieve a metal-to-metal seal
that will maintain the required performance through the full range of the well operating conditions.
• The metal of these sealing components requires sufficient ductility and elasticity to deform under the setting
conditions and flex under changing operating conditions in order to maintain the required sealing stress
throughout all well operations.
• This means the metal seal may be softer than the housing it is to be set into so the metal seal does not damage
the housing once energized or provide an opportunity for localized corrosion.
 Seal Types Ring Gaskets
• A ring gasket provides the actual seal in any flanged or studded connection and in some hub clamp
connections.
• The ring gasket is a metal seal designed to fit the grooves on each flange or hub face.
• As the studs on a flange or clamp are torqued the softer metal of the ring gasket is compressed against and
conforms to the harder metal of the face.
• Each ring gasket carries a rating for the range of pressures, temperatures and corrosive fluids that may be
present.
There are three basic styles of API approved ring gaskets:
o R-style is designed for standard ring joint grooves. R-style includes both oval and octagonal cross sections
which are interchangeable in a standard groove.
o RX-style also fits standard ring grooves. RX ring gaskets have a non-symmetrical cross section resulting in
sealing on the OD of the gasket only. This provides a pressure energized self-sealing gasket. A vertical hole
in the gasket ensures pressure is balanced.
o BX-style ring fits only flanges with BX grooves. These flanges are designed to allow face to face contact. BX
gaskets also have a pressure balancing hole.
o R/RX-Style may be used in 13.8-34.5 MPa operations while BX-Style are typically used in any operation
above 34.5 MPa.
 API 6A Metal Ring Gasket Styles
Ring gaskets are permanently deformed when energized and are designed for single use.
A ring-type gasket is placed and installed inside of the flange bolts and around the pipe bore.
It has no bolt holes and is typically used on raised face flanges since it can easily sit right on top of the flange.
Due to its composition, it can be installed without disassembling the joint.
 The Style RX is designed to fit the same groove design as a
standard style R making joints interchangeable
Style RX ring joint gaskets are a pressure-energised adaptation of the standard Style R gasket.
The RX is designed to fit the same groove design as a standard Style R, making the joints interchangeable.
 Octagonal or Oval Ring Gaskets
The octagonal type has a higher sealing coefficient than the oval.
Flanges with Octagonal grooves or flat bottom grooves will accept either style.
The oval type is the only type RTJ that will fit oval or radius grooves.
 BX Style Ring joint Gaskets
Style BX are pressure energized gaskets manufactured in accordance with API 6A and designed for use up to
20,000 psi.
All BX gaskets incorporate a pressure balance hole to ensure equalization of pressure which may be trapped in the
grooves. Style BX Spec Sheet.
 Primary and Secondary Seals
• Casing strings (other than the surface casing) that terminate in the wellhead are typically sealed twice.
• First, a primary seal is set when a casing is suspended by a casing hanger in the top bowl of a casing head or
casing spool.
• This seal isolates the annulus between this casing string and the previous casing string.
• The casing itself extends into the counterbore of the next wellhead component where a secondary seal can be
set.
• When both a primary and secondary seal are set, the seals and the connection between the two wellhead
components can be pressure tested for integrity via a test port.
• This same principle can be applied to a welded connection between the casing head and surface casing when it
is welded both on the top of the casing on the inside of the head and outside on the bottom of the casing head.
• A test port between the two welds provides a means to pressure test the integrity of the welds.
 Surface Casing Vent Flow Assembly

• Wellheads can be equipped with an assembly to isolate and test the annulus between the surface casing and
the second string of casing, and allow the annulus to vent freely.
• This assembly is commonly referred to as a Surface Casing Vent Assembly (SCVA).
• There two common types of casing vent assemblies are the conventional assembly and the annular packoff.

Conventional Surface Casing Vent Assembly

• The conventional surface casing vent assembly is connected to an outlet in the casing bowl and extends above grade
for monitoring purposes.
• Since the casing bowl forms a pressure seal to the surface casing, the SCVA can be used to determine if any flow or
pressure exists between the surface casing and the second string of casing.
 Annular Packoff

• In applications where high temperature changes are seen on the casing and wellhead it may be desirable to allow
differential expansion of the casing strings to reduce the forces seen on the wellhead.
• This is typically done by installing an annular packoff .
• The function of the annular packoff is the same as a surface casing vent assembly .
Annular Packoff Assembly
• Casing thermal expansion can be handled in several ways and is not limited to annular packoffs.
• It is the operator’s responsibility to assess whether new technologies meet all the requirements of a SCVA and
the risks of thermal service.
• A second use of annular packoff assemblies is for observation wells with external instrumentation.
• The annular packoff allows the instrument leads to be isolated below the wellhead.
• Thermal wells with annular packoff assemblies create additional design requirements over conventional SCVA.
• These need to be considered during initial wellhead design for integrity throughout the life cycle of the well.
• Consider the following:
o Fluid expansion in annular space.
o Corrosion of casing close to surface due to elevated temperatures and exposure to ground water.
• In thermal wells, water (in liquid form) in the annulus between the surface casing and the second string of casing
is heated and causes expansion.
• Restraining the expansion of this fluid can cause pressure to build past the maximum working pressure.
• The warm up phase is defined as the period in which the well is heated from ambient conditions to over the
boiling point of the water in the annulus space.
• The operator should allow free expansion of fluid in the annular spaces during warm up phase by ensuring the
surface casing vent valve and goose neck are free of obstruction (e.g., ice plug) and are maintained open .
• Packoff assemblies are not always installed on CSS wells due to the operating conditions and corrosion mitigation
programs that can be employed.
• Corrosion around the annular packoff assembly is possible in thermal wells when there is surface or ground water
in the presence of oxygen and elevated temperatures.
 Sweet Flowing Wells

• Flowing wells rely on reservoir pressure to lift production to surface.

• Flowing wellheads are typically simple but some may support multiple tubing strings, monitoring lines or
control lines.
• Depending on the type of produced fluids and well completion, production can be up the production casing,
production tubing or the tubing-casing annulus.
Wellhead for Sweet Flowing
Well ≤ 13.8 MPa
Wellhead for High Pressure Sweet Flowing Well (> 13.8 MPa)
 Critical Sour, Sour and Corrosive Wells
• The classification of critical sour typically takes into account a number of factors including H2S release rates and proximity to populated
centers.
• our wells are defined as any well having 0.3 kPa H2S PP or greater that are not designated as critically sour by local jurisdictional regulation.
• Sour wells present three major risks:
• H2S is highly toxic even at low concentrations.
• H2S is a corrosive product that can degrade both metal and elastomer components
• in the wellhead.
• Sulphide Stress Cracking (SSC) can cause mechanical failure of materials.
• The higher standard for connections and PSL for sour wells is designed to address these risks.
• Corrosive factors also need to be considered in the selection of connections and PSLs. The following all present a corrosion hazard:
o CO2 and water
o Salt water
o Aggressive solvents (e.g., Dimethyl disulphide (DMDS))
o Acid (well stimulation)
• Where corrosion is aggressive, the higher product standard for sour or critical sour wells may be equally applicable to wells with these or
other corrosive fluids.
• Damage from H2S can be accelerated when it is combined with other corrosive fluids.
• In such cases higher product and safety standards may be desirable.
Sour Well (Non-Critical) Example

Extended neck tubing hangers, complete with a back pressure

valve (BPV) preparation, should be utilized in sour well
completions.
 Fracture Trees

• The fracture tree is similar to a Christmas tree in that it is an assembly of valves and fittings placed above
the wellhead.
• The fracture tree is generally installed as a temporary system and is specifically designed to control the
fracture fluid being injected into the well.
• The tree may also be left in place during initial well flowback operations and the initial well production
phase but it is usually replaced by a permanent conventional Christmas tree at some point.
• To accommodate the fracture treatment conditions, fracture trees are usually rated to a higher pressure
and often have a larger through bore diameter than the Christmas tree that will follow.
Fracture Tree
Connections
• 5.1.6.5
• The connection between the fracture tree and the wellhead can be subjected to bending loads due
to the weight supported by the fracture tree. These loads are normally within the acceptable
capacities of the connection. If the load applied is unbalanced, such as when one larger fracturing
inlet line tied in horizontally is used, the applied bending load can stress the connection and
potentially result in a failure. Unbalanced loads need be adequately supported.
• IRP The loads imparted on the connections to the fracture tree shall not exceed the capacity of the
fracture tree connections (as per manufacturer specification).
 Wellhead Isolation Tool

A remote actuated valve or valves should be used with

wellhead isolation tools as a means to quickly close and
contain the wellhead pressure and prevent damage.
 Artificial Lift Wells
• Artificial lift is installed to increase the production rate from flowing wells or enable production at
wells that will not flow due to issues such as reservoir depletion, an inadequate inflow pressure or
an increased WOR in the produced fluid.
• Artificial lift may be installed in sweet or sour wells.
 Common Types of Artificial Lift

Any artificial lift equipment mounted on the wellhead

shall match the requirements of the operating service
(e.g., if the wellhead requires flanged connections, the
BOP connections or plunger lift assembly shall also be
flanged or have at least a comparable rating such as a
clamp hub).
If conditions have changed such that the original wellhead
requirements are no longer applicable, the current (not
original) conditions shall guide equipment design and
selection.
Lift equipment is frequently added later in the life of a
well.
 Gas Lift
• A gas lift system enables or enhances well production by injecting high pressure gas into the production fluids
to reduce the hydrostatic pressure and improve the ability to flow to surface under natural reservoir pressures.
• The high pressure lift gas is injected either into the production casing/tubing annulus or the production tubing.
• It is then introduced to the production fluid through a series of mandrels and valves installed in the production
tubing.
• Produced fluids, with their reduced density, then flow up either the annulus (if the tubing is the conduit for the
lift gas) or the tubing (if the annulus is the conduit for the lift gas).
• A downhole packer is typically included with the completion to avoid injecting gas into the reservoir.
• Annular gas injection with tubing production is by far the most common completion.
• Wellhead equipment operating with a gas lift system shall be designed to withstand the increased pressures,
corrosion and flow conditions resulting from the lift gas.
 Electric Submersible Pump
• An ESP is installed at the base of the production tubing and the completion might include a downhole packer .
• Electric power is supplied to the downhole motor by a cable that is run along the tubing from surface.
• The high voltage, high amperage power cable is passed through and sealed at the wellhead by a specially
engineered electric feedthrough connector.
• Note: The feedthrough connector is not designed to carry the weight of the cable.
• The cable is run with and banded or clamped to the production tubing string.
• Sufficient slack to avoid landing the cable in tension is required.
Wellhead for Electric
Submersible Pump
 Reciprocating Rod Pump
• A RRP artificial lift system includes a surface drive (usually a pumpjack set behind the well), a rod string and a
downhole pump.
• The rod string connects the surface driver to the downhole pump and is reciprocated vertically to activate the
pump and produce the reservoir fluid to surface.
• The wellhead includes a stuffing box and BOP.
• The stuffing box provides a dynamic seal against the polished rod.
• The BOP can be closed off against the rod to seal off the well.
Integrated Pollution Control Stuffing Box
and BOP
 Progressing Cavity Pump
• The PCP artificial lift system also includes a surface drive, rod string and downhole pump but in this technique
the rod string is rotated instead of being reciprocated.
• The PCP drivehead and stuffing box are mounted above the flow cross and, in electrically powered systems, the
electric motor also is mounted on or suspended from the wellhead.
• Note: There are pumping operations that utilize an Electric Submersible Progressing Cavity Pump (ESPCP).
• The recommendations for the ESP are more appropriate for this type of pump design.
 Wellhead for PCP Pump

Wellheads accommodating a progressing cavity pump

shall be designed with the additional demands of the PCP
drivehead taken into consideration.
Wellheads with a PCP drivehead should be made up with
flanged or studded connections to support the additional
weight of the motor or drivehead and sustain the
vibration, torque and fatigue created by the PCP
operation.
 Plunger Lift
• In a plunger lift system fluids are moved up and out of a well by a plunger that is carried up by natural
well pressures.
• At surface, the arriving plunger is captured in a lubricator, the produced fluid unloaded to the flowline
and the plunger released to fall back to the bottom of the well where the unloading cycle repeats.
• The major wellhead integrity concern with plunger lift systems is the arrival of the plunger at surface.
• In normal operations, the force of the incoming plunger is absorbed by the fluid column and springs
which stops in the lubricator assembly.
• The plunger may fail to capture fluid if well conditions change or the plunger is caught by paraffin, wax,
sand, scale or hydrate build-up in the tubing string and fails to drop to the well bottom.
• When it is subsequently pushed up by well pressure, the plunger may strike the surface assembly with
an unexpectedly high velocity and much greater impact force.
• In extreme circumstances, a plunger arriving at a high velocity without a fluid column may cause
equipment damage (wellhead or lubricator failure) and a well control incident.
• If the top flow line on the plunger lift is not tied into the outflow line, debris can build up and trap
pressure in the lubricator.
• .
 Plunger Lift System

Plunger lift impact and wear can cause loss of well

control, particularly with threaded connections between
the tubing head adaptor and plunger lift lubricator.
For new installations or conversions to a plunger lift, all
Christmas tree components, including the lower
connection on the plunger lift, shall be flanged or
studded.
Side outlets are an exception and may be threaded.
Lubricator Assembly
 Hydraulic (Jet) Pump
• A hydraulic pump is a downhole pump that is driven by pressurized fluid supplied from the surface.
• Hydraulic pumps come in a variety of designs including jet, piston and turbine pumps.
• The simplest design pumps the power fluid down the production tubing and brings the combined power and produced fluid stream to surface
through the production casing/tubing annulus.
• In another configuration where higher pressure or potentially corrosive fluids must not contact the casing, power fluid is pumped down one tubing
string and the hydraulic and production fluids brought to surface through a second tubing string.
• Hydraulic pumps often include downhole packers to avoid injecting fluid into the reservoir.
• Reciprocating or piston hydraulic pumps typically use three tubulars or conduits since the power fluid, which is re-circulated, must be kept separate
from the production fluids to avoid picking up formation fines or other particles which can cause the downhole pump to seize.
• Wells completed with a hydraulic pump require a switching valve and lubricator at surface to retrieve the pump.
• Wellhead equipment operating with a hydraulic artificial lift system shall be designed to withstand the pressures required to operate the hydraulic
pump.
• The lubricator shall include sufficient shock protection to avoid damaging equipment when the downhole pump is surfaced to change components.
• Note: With a hydraulic pump the maximum operating pressure is typically at the surface (power fluid pressure).
• The composition of the power fluid and produced fluid shall be considered when selecting wellhead components.
 Velocity String
• A velocity string is a means of enhancing production by reducing the liquid loading in a well.
• The velocity string is a small diameter tubular inserted into the production casing or tubing.
• The reduced diameter results in a higher flow velocity so the liquid can be carried to surface under natural
reservoir pressure which reduces the liquid load in the well and improves production.
• Velocity strings are most often used to de-water low rate gas wells.
• Velocity strings can be created with jointed tubing but coiled tubing is more commonly used in this application.
• The velocity string is typically hung in the tubing head below the master valve in wells with a multiple tubing
configuration.
• A single coiled tubing string may also be hung above and run through the master valve.
 Other Well Types
Injection or Disposal
• Injection and disposal wells are often configured like flowing wells.
• Wellheads in these cases may be configured with a tubing string that is isolated from the casing for the injection of fluids or
solids. In other cases, material may be injected via the production casing.
• Once pressured, injection and disposal wells function as a flowing well and must be configured as such.
• Injection or disposal wells present two areas of concern for wellhead equipment and design: pressure and injection fluid.
• Structurally, injection and disposal wells are typically identical to wellheads designed for flowing wells.
• IRP Existing and new wellheads to be used for injection or disposal purposes shall have an engineering assessment (and,
potentially modification) to ensure an adequate pressure rating and the ability to safely handle the injected fluid.
• The assessment of wellhead requirements has to address both pressure and fluid consideration with respect to backflow.
Injection can recharge the target zone which flows back the injection and produced fluids at a new and higher pressure. At
the same time, the returning fluid is a combination of injected and production fluids with unknown properties.
• An injected liquid may flow back as a gas (e.g., CO2) carrying higher pressure from the charged formation.
• A third consideration with injection wells is temperature, particularly in enhanced oil recovery (EOR) methods that rely on
steam injection.
• For SAGD and CSS recovery methods see 5.1.8.2 Thermal Operations.
• Wellhead components, connections and seals shall be rated to withstand any additional pressures or temperature variations
created by injection operations.
• Wellhead components, particularly elastomer and metal seals, shall be rated to adequately withstand any corrosive or
erosive effects created by injected fluids and gases.
• IRP Operators should consider any effects from a combination of injected and produced fluids and gases.
Basic Injection Wellhead
Examples of Injection Material
 Thermal Operations
• Wellhead recommendations for heavy oil/oil sands wells, which utilize a variety of thermal stimulation techniques to enhance oil recovery,
are available in IRP 3: In Situ Heavy Oil Operations. These recommendations cover the following topics:
• Designing wellhead for the temperatures and pressures that accompany thermal stimulation.
• Accommodating for the expansion and contraction created by temperature variations.
• Welding requirements and procedures.
• Requirements related to well control devices, surface casing vents, tubing
• hangers, stuffing boxes on rod pumped wells, pressure shut down devices, BOPs and master valves.
• The two basic designs for operations using thermal stimulation techniques are Steam Assisted Gravity Drainage and Cyclic Steam Stimulation.
• SAGD production involves twin horizontal wells each with their own wellhead. Low pressure steam, and potentially solvents, are injected into
the upper well.
• This creates a lower viscosity for the heated crude oil or bitumen, allowing it to flow along with the condensed water to the lower production
wellbore. Typically, some form of artificial lift (e.g., PCP) is used in the production well to produce the high viscosity fluid and water.
• Basically, SAGD production requires one well with an injector wellhead designed for steam injection and another with a wellhead designed
for a given method of artificial lift.
• CSS production involves injecting high pressure steam into the producing formation, allowing for a soaking period and then producing out of
the same well, typically first as a flowing well (due to the increased natural pressure from the injected steam) and then by some method of
artificial lift.
• Once production tails off again the cycle of steam/soak/produce is repeated.
• To complete this process CSS wellheads are adapted for both steam injection and artificial lift. In many cases, CSS wellheads involve a single
tubing string that is threaded directly into the tubing bonnet.
• An integral flow tee/BOP component and high temperature stuffing box are typically mounted above that.
• Additional design considerations for thermal wellheads include the need for high temperature seals and pipe swivels or spring hangers to
manage expansion and contraction with temperature swings.
• Produced fluids have a high water vapour load as well as H2S and CO2 gases. Injected fluids may also include light hydrocarbons to boost
recovery. Wellhead equipment may need to be monitored and protected from risk of higher levels of erosion.
• This may include control of production rates as well as sand or erosion probes.
• IRP The use of swivel joints on all connecting pipes should be considered for wellheads where there is the possibility of a bending moment or
side loading due to thermal expansion.
Integral Flow-Tee BOP
 Simple Steam
Injection Wellhead
for SAGD
Example of SAGD Wellhead for
Rod Pumping [steam assisted
gravity drainage (SAGD)]
Example of CSS
Wellhead (Cyclic steam
stimulation)
 Cavern Storage Well
• Cavern storage wells are naturally occurring or artificially created underground formations that can typically
store large volumes of hydrocarbon gases or liquids. They may use large diameter valves that fall outside the
scope of API 6A standards.
• These valves are covered by pipeline valve standards (i.e., API 6D or CSA Z245).
• Storage of hydrocarbons in underground formations should be consulted during design and implementation of
wellheads for cavern storage operations to ensure safe and compliant operations.
• While API 6D or CSA Z245 rated valves may be necessary in completing cavern storage wells they are not
recommended for drilling purposes.
• Wellhead design for cavern storage wells needs to consider the type of fluids that will be injected and produced
through the wellhead.
• Separate wellheads may be required for developing and operating the well, particularly where the cavern is
developed in a salt formation.
Cavern Storage Wellhead
 Observation Well
• Observation wells can be used to monitor formation conditions or the efficiency of the reservoir depletion
process.
• Depending on their function, observation wells may or may not enter the producing zone and those
completed in the overburden might not be exposed to the reservoir in situ or operating environments.
• Wellheads on an observation well, including those that do not enter a producing formation, shall be designed
for all anticipated conditions and provide for full isolation of the wellbore.
• IRP Monitoring lines of any sort installed in observation wells should be secured with a gas- tight seal.
• Electrical lines run into an observation well must meet all electric codes and electric isolation at surface .
• Cables or strings that run through and exit via wellhead equipment shall be sealed and packed off at surface
and tested to the working pressure of the wellhead.
Dual Tubing Head/Hangar
 BACK PRESSURE VALVE
• ACT type ‘H’ Back Pressure Valve are used extensively in ACT Hangers to safety seal off well pressure during
removal of the blowout preventer and installation of Christmas tree.
• Fluid may be circulated down the tubing through the Back Pressure Valve with assurance of automatic
reclosure against the tubing hanger is to be pressure tested.
ACT’s Lubricators which connect directly to the top of an X-Mas tree above the master valve are available in
various sizes and end connections and pressure ratings varying from 5,000 to 20,000 PSI both for standard and
sour service.
Operating a Lubricator is by far the most dangerous aspect of well head service work.
Therefore extreme caution has to be exercised while operating this tool.
 VALVE REMOVAL PLUGS

• All flanged or studded outlets on ACT’s casing heads, casing

spools and tubing heads are threaded for valve removal plugs.
• All plugs have standard API Line Pipe Threads and are small
enough to pass thru the valve to be removed.
• The plug is installed when the valve is to be removed.
 API Standard Dual Block Christmas Tree

Well head Equipment is an important

equipment for drilling & production .
Products conform to API Spec. 6A,and are
granted the right to use API monogram.
Wellhead equipment main include casing
head, casing spool, gate valve and pressure
guage, etc.
Casing hangers are all installed in the casing
head, casing spool.
1 .Casing Head
The casing head on the top of casing string is a key unit to connect the casing pipe, BOP and oil (gas) Production wellhead, and
also to hang casing pipes except for surface casing. Casing heads are of two types according to its hanged casing types: screw
casing head and slip casing head.
They also can be distinguished by its hanged casing layers: single casing head, dual casing head and triplex casing head and so
on.
1.1 Slip casing head
There are outlets on the two sides of the cross. One is connected with the treaded, flange, the joint, the intercepting valve and
the pressure gauge.
The other is connected with the gate valve.
Through the pressure gauge, you can observe the pressure gathering between the casing and the casing.
As necessary, open the gate valve to release the pressure.
1.2 Threaded casing head
The lower casing thread connects the surface casing.
The bottom bracket transmits the wellhead load to the ground.
There are two BT seals and applicable grease-injecting ports under the cavity.
There’s sealing plane matching the slip hanger in the cavity. There’s a jack screw on the flange, which is used to lock the wear
cover (protecting the sealing plan).
After being seated into the casing hanger, it can lock it down.
If there’s leakage at the jack screw, you can tighten the gland so as to make the seal act.
1.3 Integral thread casing head
It reduces one casing head spool and lowers the overall height of the casing head;
It reduces the connected place and the leaking position. The sealing performance is more reliable.
2.casing spool
The casing spools are main used for hanging technical casing pipe with one or few .
Valve and pressure gauge can be connected on two side of the casing spool.
The bottom of casing spool can be connected with casing head and the upper connected with oil/gas production
wellhead
3. Valves
CPNC offer series flage type gate valve(manual/hydraulic),chocke valve(manual/hydraulic, Positive /adjustable), one way valve
and surface safety valve, etc.
They are all in accordance with API Spec 6A.
 Dual Tubing Hangers
The WFT-TC-60 dual-completion hanger features a split
design, which makes it easy to run with an integral The MC-2C dual tubing hangers are housed in the TFF-FC
tubing spools. They consist of a body and two hanger nipples.
compression-type annulus seal, actuated by lockdown
They are designed to lower the two tubing strings
screws. Tubing strings can be run separately or
simultaneously for operational flexibility. This hanger simultaneously. Each nipple has an upper female thread for
maneuvering, and a bottom female thread for hanging the
provides maximal clearance for gas-lift valves,
subsurface safety valves (SSSVs) and packers to avoid tubing. The nipples have an extended neck to isolate the well
pressure and allow the flanged connection to be tested.
hang-ups. Each half of the hanger has internal Type H
Both nipples are threaded for a type H back-pressure valve
BPV threads for extra safety. The storm mandrel in each
hanger half is a standard safety feature. (BPV).
Subsea X-mass
 Subsea Trees
The functional requirements
o It is a vital component in the well integrity barrier envelope.
o It attaches to the wellhead and directs flow through a series of valves to the flowline.
o It is used to isolate flow from the well.
o Flow is regulated at the choke that is normally attached to the tree downstream of the wing valves.
o It provides access for well intervention operations.
o Subsea trees differ from surface trees in several important respects:
o The method of connecting the tree to the wellhead.
o Specialist equipment is required to install the tree
o All tree functions must be capable of remote operation.
o It is possible for external fluid (seawater) to leak into the wellbore.
• There are three types of tree in widespread use throughout the industry: the conventional dual bore vertical tree; the vertical mono-bore
tree; and the horizontal tree, sometimes called the spool tree.
Conventional dual bore vertical trees
• Conventional dual bore trees have a 5 in. production bore and a 2 in. annulus bore through the body of the tree. Flow from the production
bore is isolated using the master valve and/or production wing.
• Most trees have two master valves (upper and lower).
• A swab provides access to the production bore for intervention purposes.
• A smaller secondary bore (2 in. nominal ID) is used to access, monitor, and vent the annulus.
• Most trees have only a single master valve and a swab valve on the annulus side (Fig. 13.10).
• External pipework connects the production bore to the annulus bore.
• Opening cross-over valves in the pipework allows pressure building up in the annulus to be vented into the flowline downstream of the
production wing valve.
• After running the completion and plugging the well, the tree is run and locked onto the wellhead high pressure housing using a dedicated
dual bore tree running riser package. The riser system is also used for well interventions.
Enhanced (large bore) vertical tree
• With the “industry standard” 5 in.×2 in. dual bore vertical tree, tubing sizes larger than 5½ in. could only be run if the completion was reverse
tapered below the tubing hanger.
• Although some 7 in. completions were run below 5 in.×2 in. vertical trees, the design was far from ideal.
• A reverse taper can give access problems, and the cross-over below the hanger is subjected to very high stress.
• Conventional dual bore vertical trees also need a dedicated dual bore riser for tree deployment and well intervention.
• The introduction of large bore vertical trees has combined most of the advantages of horizontal and vertical trees.
• A large through bore allows large tubing (typically up to 7 in.) to be run without having to reverse taper below the hanger.
• A dedicated riser system is not needed; the tree can be run on drill pipe.
• Intervention access is possible with a mono-bore riser system, available as a rental package when required.
• The riser system allows circulation with fluid returns through a large bore hose in the control umbilical (Fig. 13.11).
• During the landing of the tubing hanger, a production port on the hanger body is aligned with its counterpart in the
spool of the tree and is the main flow conduit when the well is producing.
• Additional ports within the spool provide access to the production (“A”) annulus.
• Annulus pressure can be vented to the production flowline through a cross-over loop controlled by gate valves (Figs.
13.13 and 13.14).
Figure
13.10. Conventional
(vertical) subsea tree.
Figure 13.11. Drill-Quip
Single Bore subsea tree.
Figure 13.12. Horizontal (spool) tree.
Figure
13.13. Horizontal
tree valve
configuration.
Appendix B: API Tables
API Material
Requirements
This table is taken from
API 6A. In API 6A it is
Table 3.
API Temperature
Ratings
This table is taken
from API 6A. In API
6A it is Table 2.
Table 12 - Pressure Derating of API 6B Flanges at Elevated Temperatures
Stud sizes & Rig Gasket size
THANK YOU